SEED helps realize the low-carbon energy and materials transition through the research and development of sustainable electrochemical technology. Current R&D projects include:
- Development of PCEC for CO2 Methanation using Steam and Electricity
WHAT
ECOMET delves into the development of new electrode materials, cell designs , stack and system scale-up for e-methane production from CO2 and steam using proton-conducting ceramic electrolysers.
WHY
Nowadays, there is a global effort to find carbon-free alternatives to meet the worldwide energy and chemical feedstock demand. One of the more attractive alternatives is the production of green hydroagen and fuels derived from it. However, there are still several challenges for integrating green hydrogen technology with current industrial processes (e.g., Haber-Bosch, Sabatier or steam reforming reaction). In this landscape, intermediate temperature (400°C - 600°C) electrolysis becomes more attractive, mainly due to two reasons: The first one is related to their inherent higher efficiency compared to lower temperature approaches such as Proton exchange membrane electrolysis (PEM) or alkaline electrolysis. And the second one is the possibility of integration with thermochemical reactions, such as the methanation reaction, due to their operation temperature range. Consequently, the use of proton-conducting ceramic electrolyser cells (PCEC) is becoming more attractive, due to their temperature of operation window and the subsequent allowance to use a low-cost catalyst and simpler assembly design. This project investigates avenues to increase the competitiveness of this technology using both experimental and computational tools, with coke formation on the cell electrodes, low methane selectivity at high temperatures (> 400 °C) and the exothermic nature of the methanation reaction, being the main challenges to overcome.
HOW
The project combines both experimental and modelling approaches. The experimental side, led by German partners EIFER and WZR Ceramics, focuses on the development of novel electrode catalysts and cell architectures, including via 3-D printing of ceramics. The modelling half, led by Dutch partners U Twente and Shell, involves the development of new numerical methods, encompassing the processing of experimental data and multi-scale cell, stack and system simulation to facilitate optimal technology design, scale-up and ecomonic evaluation.
FUND&COLAB
This is a bilateral NWO-BMBF DE-NL project funded by the Dutch Science Foundation (NWO) and the German Ministry of Economic Affairs (BMBF) and co-funded by Shell and WZR Ceramics.
WHO
The modelling work at U Twente is done by Ir. Antonis Vladikas and Dr. Julian Restrepo. The project is supervised by Dr. Aayan Banerjee.
- Design of durable MS-SOEC
WHAT
The project contains two parts. First is the design of a MS-SOEC. The cell design will be optimized in terms of layer thicknesses and microstructure. The cell design is then scaled up to a stack and eventually to a system. Second, the degradation of a (metal supported-) cell is investigated. The focus is on the migration of nickel in the fuel electrode during operation, i.e. Ni coarsening and depletion. The influence of different parameters like steam concentration, overpotentials, temperature and morphology will be investigated.
WHY
Compared to other types of electrolysers such as alkaline and PEM, solid oxide electrolysers are not yet at the same competitive level. The two things which hold the technology back are the heat demand during operation and the relatively high degradation rates. In this project, both of these shortcomings are addressed by developing a metal supported cell and investigating Ni migration. In a MS-SOEC, the functional layers are thinner than conventional solid oxide cells, which allows for operation at lower temperatures. Moreover, the high degradation rates are mostly attributed to the depletion of nickel near the electrolyte. The mechanism behind the movement of nickel is actively debated in the scientific community.
HOW
For the design and optimization of the MS-SOEC a 1-dimensional model is made of the membrane electrode assembly. After the optimization of the functional layers, the 1D model is connected to a channel model. The channel model will be validated with a to-be-built experimental setup. The setup will be able to test large planar cells and will be fitted with in situ gas composition analysis and segmented cell testing capabilities to observe gradients (temperature, current distribution, gas composition) across the cells. Ni migration will also be investigated experimentally using accelerated stress test protocols inside a button-cell test rig. The experiments will be used to verify existing hypothesis or develop a new one.
FUND&COLAB
The project is part of the NXTGEN HIGHTECH programme on the development of a new generation of electrolyzers to be made in the Netherlands. The NXTGEN HIGHTECH program is funded by the Nationaal Groeifonds of the Netherlands. Inside the project, we collaborate closely with TNO, HyGear, VSparticle, Spark-nano and Admatec.
WHO
The work for the project is done by Ir. Wisse Hersbach. He obtained his Bachelor and Master degrees at the University of Twente in Chemical Engineering. For his master thesis he worked on dense hydrogen separating membranes, specifically on the material Lanthanum Tungstate, which he finished Cum Laude. The work is done under supervision of Dr. Ing. A. Banerjee.
- Development of fuel-flexible PCFC
What
This project aims to develop fuel-flexible proton-conducting ceramic fuel cells (PCFCs) with high performance and long-term durability. The developed cells are expected to operate optimally with a variety of fuels, such as hydrogen (H₂), carbon monoxide (CO), methane (CH₄), ammonia (NH₃), and methanol (CH₃OH). To ensure the long-term stable operation of the cell, a digital twin will be developed. The digital twin monitors the health of the PCFC during operation, enabling the identification of control strategies to mitigate performance degradation.
Why
Proton-conducting ceramic fuel cells (PCFCs) are emerging as a key technology in the realm of energy conversion, attracting widespread attention due to their ability to utilize a diverse array of fuels, including hydrogen, methane, ammonia, and syngas. They can also, potentially, be operated reversibly, converting chemical fuels to electricity (fuel cell mode) and vice versa (electrolysis cell mode), at high efficiencies and zero emissions. However, the long-term stability of PCFCs is a matter of great concern, especially when using fuels such as NH3 and methane. Operation under these fuels can lead to cell coking and nitridation, which block active sites and result in reduced performance. Furthermore, recent research has identified elemental diffusion of Ni into the electrolyte phase, leading to the formation of a cumulus cloud-like structure that corresponded to Ni element segregation at the grain boundaries in the electrolyte. This results in increased grain boundary resistance and degradation of device performance. Thus, developing PCFCs that optimize not just performance, but also long-term stability is vital. Predicting the performance degradation of PCFCs during operation is also necessary to develop control strategies to extend operational life and facilitate predictive maintenance, reducing costs.
How
In the initial phase of the project, BaZrCeYO3-δ-based fuel electrode-supported cells will be fabricated using conventional pressing and coating methods. In the second phase of the research, a series of promising electrolyte compositions will be selected, synthesized, and used to fabricate PCFCs. These cells will then be tested under various fuel conditions with the goal of achieving a degradation rate of less than 0.3% in voltage over 300 hours of operation. In parallel, a digital twin of the PCFC will be developed to predict the degradation rate and the remaining useful lifetime (RUL). The digital twin will connect physics-based models to real-time measurement data via ensemble artificial neural networks.
FUND&COLAB
The project is part of the HyUSE program, which focuses on the development and assessment of hydrogen technology to accelerate its adoption in the Netherlands. It is supported by the GroenvermogenNL National Growth Fund, aimed at advancing the development and deployment of hydrogen applications, contributing to climate goals, and strengthening the Dutch economy. Within the project, we collaborate closely with partners including University of Groningen, Utrecht University, Avans University of Applied Sciences, HyET NoCarbon, Shell, and LyondellBasell Industries.
Who
The work is carried out by Dr. Ahmad Shaur and Ir. Jorik Bloemenkamp. Ahmad Shaur obtained his PhD degree at the University of Twente in the Inorganic Membranes group. His PhD work focused on developing suitable electrodes for solid oxide cells (SOCs) used in CO2 electrolysis and conducted key research to investigate the hybrid plasma-electrolysis technology. Jorik Bloemenkamp obtained his Bachelor and Master degrees at the University of Twente in Chemical Engineering. For his master thesis he worked on artificial photosynthesis. This work is done under the supervision of Dr. Ing. A. Banerjee.
- Development of Advanced Diagnostic and Monitoring Tools for Green Hydrogen Electrolysers
WHAT
To develop durable, safe and cost-effective electrolyser technologies, it's crucial to identify and monitor key condition parameters in-operando. As part of the DELYCIOUS project, this work focuses on two main aspects. First, it involves developing physics-based models for proton exchange membrane (PEM), alkaline (AEL), and solid oxide (SOEC) electrolysers at both cell and stack scales. These models will generate extensive datasets to train machine learning algorithms, enabling predictive diagnostic tools that enhance efficiency, reliability, and long-term durability of electrolyser systems. By incorporating experimental degradation data, performance factors like cell voltage, current density, and hydrogen crossover into the oxygen compartment can be assessed by the multiphysics model-based condition monitoring tool.
HOW
The modelling work is carried out in two phases. First, 1D continuum multiphysics models for PEM, AEL are developed, coupling mass, momentum, and charge transport while integrating accelerated degradation parameters through kinetic and structural correlations. These models are validated using key performance metrics such as cell voltage and hydrogen crossover, generating multidimensional datasets to train machine learning algorithms for predictive diagnostics. In the second phase, the validated cell models are scaled up to full-stack configurations, incorporating cell-to-cell interactions and thermal variations. This enables the development of diagnostic tools for real-time monitoring and predictive maintenance of real-world electrolyser stacks, ensuring optimal performance and durability in industrial applications.
The experimental work will begin with the installation of advanced diagnostic and monitoring tools, based on electrochemical impedance and Raman spectroscopy, in our SOEC performance testing lab for operando degradation studies. Accelerated degradation experiments will then be conducted on cell-scale SOECs over a prolonged period (>1000 hours) to capture long-term degradation trends and identify important condition parameters. The generated data, including key degradation mechanisms, will be used to refine the SOEC cell-scale model, improving its accuracy in predicting performance loss and failure model. Subsequently, the condition monitoring tool will be used to mitigate the performance degradation of the cell-scale SOEC during operation by controlling the identified condition parameters and improve cell lifetime.
WHY
The transition to a carbon-neutral future relies on efficient and durable green hydrogen electrolysers. Over time, membranes degrade and thin, catalysts deteriorate, and hotspots form, all reducing performance and lifetime. These degradation mechanisms can cause, for example, hydrogen in PEM electrolysers to permeate into the oxygen compartment, resulting in diminished product purity and creating flammable mixtures that pose explosion hazards. Additionally, SOECs operating at high temperatures and high vapor pressures can experience issues such as electrode and electrolyte delamination, leakage, and materials degradation. Furthermore, integrating electrolysers with intermittent renewable energy sources, such as wind and solar power, introduces fluctuating power inputs. This fluctuation can accelerate electrolyser degradation and increase associated safety risks.
The DELYCIOUS project addresses these challenges by combining accelerated degradation tests with physics-based models and data-driven condition monitoring schemes. This approach provides critical insights into performance loss and safety hazards, aiding in the optimization of the three green hydrogen electrolyser technologies and the development of robust condition monitoring and diagnostic tools.
FUND & COLLABORATION
This project is part of the DELYCIOUS initiative, funded by Horizon Europe and the EU Clean H₂ Partnership. DELYCIOUS brings together leading industrial and academic partners, including Air Liquide, Fraunhofer IWES, Horiba France, Dumarey Softronix, ETA Florence, Stargate Hydrogen, Sivonic, and the University of Twente, to develop advanced diagnostic tools for Hydrogen electrolysers.
WHO
The modelling work in this project is carried out by Esaar Naeem Butt. During his PhD, Esaar developed physicochemical models to study CO2 electrolysis and investigated structural and operational strategies to create an optimal reaction environment. The experimental work on SOEC degradation is conducted by Dr. Bishnu Choudhary, who has extensive experience in the fabrication, characterization, and testing of protonic ceramic and solid oxide cells. This work is done under the supervision of Dr. Ing. A. Banerjee.